To hose used to install loose fill insulation

ABSTRACT

An improved hose is used to install loose fill insulation. The hose includes projections extending from an inner surface which serve to condition the insulation as it proceeds through the hose and is dispensed. In a first exemplary embodiment of the present invention, the projections are formed so as to be perpendicular to a longitudinal axis of the hose. In a second exemplary embodiment of the present invention, the projections are formed so as to be angled, by an angle less then ninety (90) degrees with respect to the longitudinal axis of the hose. In a third exemplary embodiment of the present invention, the projections are formed with a serrated edge. In a fourth exemplary embodiment of the present invention, the projections are formed as part of a cap member which is disposed around the periphery of the hose. In a fifth exemplary embodiment of the present invention, the projections include an additional perpendicular projection member extending therefrom.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is related to, and claims priority of, co-pending U.S.application Ser. No. 09/817,429 filed Mar. 26, 2001, entitledIMPROVEMENT TO HOSE USED TO INSTALL LOOSE FILL INSULATION.

FIELD OF THE INVENTION

The present invention relates to hoses, and in particular, a hose forinstalling loose fill insulation.

DESCRIPTION OF THE RELATED ART

Loose fill insulation is packaged in bags in which the material becomescompacted during storage and shipment. When removed from the bags, theinsulation separates into clumps. In order to effectively install theinsulation material, it must first be “fluffed up” or conditioned toreduce its density. Traditionally, pneumatic devices are used to bothinstall the insulation and perform the conditioning. The conditioningprocess breaks up the clumps and then “fluffs” or “opens up” theinsulation. The conditioned insulation is then applied pneumatically toan area by blowing it through a hose connected to the pneumatic device.The insulation may be moistened and/or treated with an adhesive in thepneumatic device before installation.

FIGS. 5(a) and 5(b) show an example of a prior art pneumatic apparatus10 for dispensing loose fill insulation. FIG. 5(a) is an isometric viewof the apparatus 10, showing a hopper 16 for storing loose fillinsulation, blower 22, and a hose 26 for dispensing the insulation. FIG.5(b) is a side view of the apparatus 10 showing the inner workings indetail. The apparatus includes shafts 52, 60 with spikes 54, 62extending therefrom for conditioning the insulation, which is placed inthe hopper 16.

The spikes 54, 62 break apart the clumps of insulation and prepare it tobe dispensed.

The conditioned insulation passes from the hopper 16 through the spikes54, 62 to dispensing assembly 20, where it is blown through hose 26 byblower 22. In operation, the user simply points the hose 26 where hedesires the insulation, and it is dispensed.

Often, the conditioning which occurs within the insulation dispensingapparatus is not enough to fully “open up” the insulation. If theinsulation is not sufficiently conditioned when it leaves the dispensingapparatus it may be applied unevenly (i.e. in clumps), and it may nothave the manufacturer's specified density for the installed thermalresistance desired. Conversely, insulation which is well conditionedallows adhesive and moisture to penetrate the insulation fibers, andapplies to surfaces more evenly. Thus, there is currently a need for animproved device for increasing the conditioning of loose fillinsulation.

SUMMARY OF THE INVENTION

The present invention is a tube for enhancing the conditioning of loosefill insulation. The tube preferably comprises a hose for dispensingloose fill insulation in an insulation dispensing apparatus. The tubeincludes projections formed around its inner periphery which serve tocondition the insulation as it passes from one end of the tube to theother.

The above and other advantages and features of the present invention arebetter understood from the following detailed description of thepreferred embodiments of the invention which is provided in connectionwith the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1(a) is a front elevation view of the tube of the presentinvention.

FIG. 1 (b) is a top plan view of the tube of FIG. 1(a).

FIG. 2(a) is a cross-sectional view of the tube of the present inventionwith a projection according to a first exemplary embodiment.

FIG. 2(b) is a cross-sectional view of the tube of the present inventionwith a projection according to a second exemplary embodiment.

FIG. 2(c) is a cross-sectional view of the tube of the present inventionwith a projection according to a third exemplary embodiment.

FIG. 2(d) is a cross-sectional view of the tube of the present inventionwith a projection according to a fourth exemplary embodiment.

FIG. 3 is the a cross sectional view of the tube showing how the websare attached to one another.

FIG. 4 is an exemplary method of forming the hose of the presentinvention.

FIG. 5(a) is an isometric view of a conventional apparatus fordispensing loose fill insulation.

FIG. 5(b) is a cutaway side elevation view of the apparatus fordispensing loose fill insulation shown in FIG. 5(a).

FIG. 6 is a cross-sectional view of the tube of the present inventionwith a projection according to a fifth exemplary embodiment.

DETAILED DESCRIPTION

In a conventional insulation dispensing apparatus, such as the onedescribed above and shown in FIGS. 5(a) and 5(b), loose fill insulationis placed into a hopper or housing of the apparatus where it isconditioned. The apparatus typically includes a mechanism forconditioning the insulation, as well as means for dispensing theinsulation, such as a hose or other similar means. Sometimes, however,the conditioning mechanism within the dispensing apparatus does notprovide sufficient conditioning. The present invention comprises animproved hose or tube 100, for attachment to an insulation dispensingapparatus. The hose or tube 100 includes a projection 140 along itsinner surface 150 which serves to condition loose fill insulation as itpasses through the tube.

The present invention comprises a tube 100 for dispensing loose fillinsulation. The tube 100 preferably comprises a flexible hose coupled toan insulation dispensing apparatus. In FIGS. 1(a) and 1(b), the tube 100is formed as a cylindrical hose having an approximately circularcross-section. However, the tube 100 may have a cross-section of avariety of shapes (e.g. oval, rectangular, polygonal) without departingfrom the scope of the invention. Further, although it is preferred thatthe tube 100 be used as a flexible external hose for an insulationdispensing apparatus, the tube 100 may be formed as an internalcomponent in an insulation dispensing apparatus which is either rigid orflexible. Alternately, the tube 100 may comprise the inner liner of ahose.

The tube 100 comprises an inner web 130 surrounded by an outer cap 120.In the exemplary embodiment shown in FIGS. 1(a) and (b), the inner web130 is formed in a cylindrical shape, and the outer cap 120 is formed asa helical member extending around the outer periphery of the inner web120. The inner web 130 includes a first helical projection 131 whichextends around its entire outer periphery. The inner web 130 alsoincludes a second helical projection 140 which extends around its innerperiphery which is shown specifically in FIGS. 2(a)-2(d). The firsthelical projection 131 extends away from a longitudinal axis A of theinner web 130, and the second helical projection 140 extends towards thelongitudinal axis A of the inner web 130. The outer cap 120 comprises ahelical member 121 which is wound around the outer periphery of theinner web 130 and which is disposed at a position substantially alignedwith helical projection 140, and in between portions of the helicalprojection 131.

FIG. 2(a) shows a cross-sectional view of the tube 100 of the presentinvention taken along section line 2(a)—2(a) in FIG. 1(a). FIG. 2(a)shows a first exemplary embodiment of the helical projection 140 of thepresent invention. Reference numeral 150 indicates the inner portion ofthe tube 100 generally, and reference numeral 160 indicates an outerportion. Insulation (indicated by the arrow) passes along inner portion150 as it is dispensed through the tube 100. The helical projection 140of inner web 130 extends into the inner portion 150 of the tube 100 by aspecific length, typically {fraction (1/1000)} of an inch (0.025millimeters) to ¼ of an inch (6.35 millimeters), depending on the lengthof the insulation fiber and the diameter of the tube 100. Thus, thehelical projection 140 provides a small partial obstruction in the pathof insulation traveling through the tube 100.

In operation, as insulation is blown through the tube 100 by aninsulation dispensing apparatus, the insulation collides with thedifferent portions of helical projection 140, and is further “opened up”or conditioned. The individual fibers of the insulation are essentially‘grabbed’ by the projection 140 as they pass through the tube 100. As aportion of the fiber is attached to the projection 140, the flow of airthrough the tube 100 causes the fiber to become stretched. Thisstretching action causes the insulation which exits the tube 100 to bebetter conditioned (i.e. less dense) than the insulation which entersthe tube. In particular, the present invention lowers the density of theinsulation fibers by approximately 10-20%. Accordingly, insulationinstalled using the tube 100 of the present invention is less clumpy andadheres better to the surface to which it is applied than insulationinstalled by conventional hoses.

Although FIG. 2(a) shows the helical projection 140 as beingsubstantially perpendicular to the axis A of the tube 100 (shown in FIG.1(a)), other exemplary embodiments of the present invention are alsocontemplated by the inventor.

FIG. 2(b) shows a second exemplary embodiment of the present inventionwhere the helical projection, now labeled 140′, is angled with respectto the axis A of the tube 100 by an angle less then ninety (90) degrees.The exemplary projection 140′ is angled so that it points towards thedirection from which insulation flows through the tube in FIG. 2(b),however, the projection can alternately be angled in the oppositedirection. The angling of the projection 140′ can be accomplished in oneof two ways. The projection 140′ can be angled by extruding the innerweb 130 with an angled projection. Alternately, the projection can beformed by extruding the inner web 130 as it is shown in FIG. 2(a), andangling the projection during manufacture by controlling the forwardthrust of a rotating mandrel 200 (shown in FIG. 4) as the tube 100 isfabricated. The process for extruding the inner web 130, as well as thefabrication process for the tube 100, is explained in detail below withrespect to FIGS. 3 and 4.

FIG. 2(c) shows a third exemplary embodiment of the present inventionwhere the helical projection, now labeled 140″, is formed to have aserrated edge 141. This serrated edge 141 can be formed by extruding theinner web 130 with a serrated edge as explained below.

FIG. 2(d) shows a fourth exemplary embodiment of the present inventionwhere a modified outer cap 120′ forms the helical projection, nowlabeled 142. Again, by changing the profile of the die used tomanufacture the outer cap, the structure of the fourth exemplaryembodiment can be accomplished as explained below.

FIG. 6 shows a fifth exemplary embodiment of the present invention wherea first portion 241 of a helical projection 240 includes a projection245 extending perpendicularly therefrom. A second portion 242 of thehelical projection 240 does not include such a perpendicular projectionin the exemplary embodiment, but may alternatively include such aperpendicular projection. In the fifth exemplary embodiment, theprojection 245 performs a stabilizing function during manufacture of thetube 100. In particular, when an outer cap tape 170 is wrapped around aninner web tape 160, the projection 245 maintains the first and secondportions 241, 242 of the helical projection 240 in a parallelrelationship with respect to each other, and in a orthogonalrelationship with respect to the primary axis of the insulation hose.Without this stabilizer projection 245, the first and second portions241, 242 of the helical projection 240 have a tendency to collapseagainst each other during manufacture (an undesirable result). Thestabilizer projection 245 prevents this condition by providing animpediment to the collapse.

In the fifth exemplary embodiment, reference numeral 250 indicates aninner portion of the tube 100 generally, and reference numeral 260indicates an outer portion. Insulation (indicated by the arrow) passesalong inner portion 250 as it is dispensed through the tube 100. Thehelical projection 240 of inner web 230 extends into the inner portion250 of the tube 100 by a specific length, typically {fraction (1/1000)}of an inch (0.025 millimeters) to ¼ of an inch (6.35 millimeters),depending on the length of the insulation fiber and the diameter of thetube 100. Thus, the helical projection 240 provides a small partialobstruction in the path of insulation traveling through the tube 100.

FIGS. 3 is a cross sectional view of the tube 100 showing how the innerweb 130 (with helical projection 140) and outer cap 120 are formed. FIG.3 shows an inner web 130 having a helical projection 140 as shown inFIG. 2(a), but the foregoing explanation applies equally as well toexemplary embodiments shown in FIGS. 2(b)-2(d). The materials for boththe inner web 130 and outer cap 120 are preferably formed by extrusionof plastic through a die. The plastic may comprise any well knownplastic in the art, for example, polypropalenes, urethanes, andpolyvinyl chlorides may be used. However, these components need not beformed of strictly plastic, and may be formed of any suitable materials,including metals (e.g. aluminum), by any suitable process known to thoseskilled in the art. The inner web 130 is not formed as a cylindricalmember as it is shown in FIGS. 1(a) and 1(b). The web 130 is actuallyformed as a tape extrusion 160 with a W-shaped cross section as shown inFIG. 3. The tape 160 is wrapped around a cylindrical rotating mandrel200 (shown in FIG. 4) to form the cylindrical inner web 130 shown inFIGS. 1(a) and 1(b). The mandrel 200 rotates in either the clockwise orcounter-clockwise (as shown in FIG. 4) direction to roll the tape 160onto its outer surface. FIG. 3 shows a cross section of two segments ofthe tape 160. Each segment of the tape 160 has a W-shaped cross sectionwith a inverted V-shaped central portion 161, and two L-shaped outerportions 162. The central portion 161 of the W-shape, when wound aroundthe mandrel 200, creates the first helical projection 131 of the tube100, and outer portions 162 create the second helical projection 140.The outer portions 162 are preferably formed so that lower portions 163thereof extend below the central portion 161 by a distance Dapproximately {fraction (1/1000)} of an inch (0.025 millimeters) to ¼ ofan inch (6.35 millimeters), depending on the length of the insulationfiber and the diameter of the tube 100. The projections 163 of the innerweb tape 160 create the helical projection 140 when tape 160 is woundaround the cylindrical mandrel 200.

The outer cap 120 is also formed from a tape-like extrusion 170. Theouter cap tape 170, however, is formed to have an inverted U-shape. Theouter cap tape 170 is formed to fit over at least two outer portions 162of the inner web tape 160 as shown in FIG. 3. The central open portionof the U-shape is approximately the same width and length as thecombined width and length of the two adjacent outer portions 162. Asmall gap 180 exists between the adjacent outer portions 162 of thesegments of tape 160. The outer cap tape 170 covers the two adjacentouter portions 162 and gap 180, and thus holds the different segments ofthe inner web tape 160 together to form tube 100.

As stated above, the inner web 130 and outer cap 120 can be manufacturedto have different configurations than the one shown in FIG. 3. Theexemplary embodiment of FIG. 2(b) can be fabricated by extruding aninner web where the outer portions 162 of the inner web tape 160 areangled by an angle less than ninety (90) degrees with respect to thecentral portion 161. This involves merely changing the die used toextrude the inner web tape 160. The exemplary embodiment shown in FIG.2(c) can be formed in a similar manner by changing the shape of the dieused to extrude the inner web tape 160 to have a serrated edge. Theexemplary embodiment of FIG. 2(d) can be formed by changing the shape ofthe die used to extrude the outer cap tape 170.

FIG. 4 shows an exemplary method of forming the tube 100 of the presentinvention from the inner web tape 160 and outer cap tape 170. The innerweb tape 160 is wound around the cylindrical rotating mandrel 200 toform the cylindrical shape of tube 100 shown in FIG. 1 (a). As the tape160 is wound around the mandrel 200, the outer cap tape 170 is meltedonto the web 130. As stated above with reference to FIG. 2(b), theforward thrust of the mandrel can be controlled so as to create ahelical projection 140 which is angled by an angle of less than ninety(90) degrees with respect to the axis A of the tube 100. This isaccomplished by forcing the mandrel 200 forward (in the direction shownby arrow) while it is rotating. This forward thrust pulls theprojections 163 of the web tape 160 in the direction of the force, andthus creates a tube 100 as is shown in FIG. 2(b).

The outer cap tape 170 is secured to the inner web tape 160 by injectingmolten plastic into the area around the cap as it is wound around themandrel 200. The cap 120 is melted onto the web 130 at gap portions 180formed between the segments of the tape as it is wound around themandrel 200. Thus, the cap 180 seals the different segments of the innerweb tape 160, and holds the tube 100 together. The shape of the tube 100may be altered by simply changing the shape of the mandrel 200.

Although the above explanation describes the inner web 130 as beingformed in a helical shape, it may be formed in other ways withoutdeparting from the scope of the invention. Instead of being formed as acontinuous helical member, the inner web 130 may be formed by a seriesof non-continuous rings. The non-continuous rings may be formed bymanufacturing the tube 100 as described above, and thereafter cuttingthe helical member 140, using for example a rotating knife die, atdifferent portions so that a plurality of non-continuous rings areformed. The cross section of a tube 100 manufactured in such a mannerwould appear the same as the cross sections shown in FIGS. 2(a)-2(d) and3, the only difference being that the projection 140 would comprise aplurality of cylindrical projections rather than one continuousprojection.

Although the invention has been described in terms of exemplaryembodiments, it is not limited thereto. Rather, the appended claimsshould be construed broadly, to include other variants and embodimentsof the invention which may be made by those skilled in the art withoutdeparting from the scope and range of equivalents of the invention.

What is claimed is:
 1. A tube comprising: an inner web having a helicalprojection disposed along an inner surface thereof and extending towardsa longitudinal axis of the inner web; and a cap disposed around an outerperiphery of the inner web, wherein the helical projection is formed ofat least two separate members separated by a specified distance.
 2. Thetube of claim 1, wherein the cap comprises a helical extrusion disposedalong the outer periphery of the inner web.
 3. The tube claim 1, whereinthe helical projection extends away from the inner surface of the innerweb in a range approximately 0.025 millimeters to 6.35 millimeters. 4.The tube of claim 1, wherein the tube comprises a hose for dispensingloose fill insulation, wherein the helical projection conditions theinsulation as the insulation passes through the hose.
 5. The tube ofclaim 1, wherein the outer periphery of the inner web includes a helicalshape having a substantially W-shaped cross section.
 6. The tube ofclaim 1, wherein the inner web is formed from an extrusion comprising: afirst central portion which is substantially V-shaped; a second portioncomprising two substantially horizontal members, each member attached toan opposing side of the first portion; a third outer portion comprisingtwo substantially vertical portions connected to the horizontalportions, the horizontal portions being disposed between the verticalportions; and, a fourth portion which extends away from at least one ofthe two substantially vertical portions of the third outer portion. 7.The tube of claim 6, wherein the fourth portion extends in a directionsubstantially orthogonal to the at least one substantially verticalportion.
 8. The tube of claim 1, wherein the inner web and cap are madeof plastic.
 9. An extrusion for an inner web of a hose comprising: afirst central portion; a second portion comprising two substantiallyhorizontal members, each member attached to an opposing side of thefirst portion; a third outer portion comprising two substantiallyvertical portions connected to the horizontal portions, at least one ofthe vertical portions extending below the horizontal portions, thehorizontal portions being disposed between the vertical portions; and, afourth portion which extends away from at least one of the twosubstantially vertical portions of the third outer portion.
 10. Theextrusion of claim 9, wherein the first central portion is substantiallyV-shaped.
 11. An apparatus for dispensing insulation comprising: acontainer for storing and dispensing insulation; and a tube coupled toreceive insulation from the container, the tube comprising an inner webhaving a helical projection disposed along an inner surface thereof andextending towards a longitudinal axis of the inner web, and a capdisposed around an outer periphery of the inner web, wherein the helicalprojection is formed of at least two separate members separated by aspecified distance.
 12. The apparatus of claim 11, wherein the capcomprises a helical extrusion disposed along the outer periphery of theinner web.
 13. The apparatus of claim 11, wherein the projection extendsaway from the inner surface of the inner web in a range approximately0.025 millimeters to 6.35 millimeters.
 14. The apparatus of claim 11,wherein the tube comprises a hose for dispensing loose fill insulation,wherein the helical projection serves to condition the insulation as theinsulation passes through the hose.
 15. The apparatus of claim 11,wherein the outer periphery of the inner web includes a helical shapehaving a substantially W-shaped cross section.
 16. The apparatus ofclaim 11, wherein the inner web and cap are made of plastic.
 17. Amethod for making a tube comprising the steps of: extruding an inner webhaving projections extending inward radially; extruding an outer cap;and, wrapping the inner web around a rotating mandrel while melting theouter cap onto the inner web wherein the projections are formed of atleast two separate members separated by a specified distance.
 18. Themethod of claim 17, wherein the inner web is formed from an extrusioncomprising: a first central portion; a second portion comprising twosubstantially horizontal members, each member attached to an opposingside of the first portion; a third outer portion comprising twosubstantially vertical portions connected to the horizontal portions,the horizontal portions being disposed between the vertical portions;and, a fourth portion which extends away from at least one of the twosubstantially vertical portions of the third outer portion.
 19. Themethod of claim 18, wherein the first central portion is substantiallyV-shaped.
 20. The method of claim 18, wherein the step of melting thecap onto the inner web comprises: melting the cap onto the inner web soas to substantially cover the third outer portion of the web.
 21. Themethod of claim 17, wherein the tube comprises a hose for dispensingloose fill insulation.
 22. The method of claim 17, wherein the outer capis formed from an extrusion having a substantially U-shaped crosssection.
 23. The method of claim 17, wherein the inner web and outer capare made of plastic.